How To TIG WELD Aluminum

How To TIG WELD Aluminum

The advantages of aluminum are numerous. For many projects, it is an ideal choice because of its advantages. Aluminum can therefore be TIG welded. If you want to become a welder, then you must know How To TIG WELD Aluminum.

If you are a beginner and don’t have any previous experience, then this article will help you to upgrade your knowledge and make you more passionate about learning. TIG welding on aluminum is covered in detail in this article. This guide provides the best information for anyone new to welding aluminum from current settings to weldability with other materials. Now is a good time to start. But if you want to purchase TIG welder under 500, It is necessary to select the welder wisely.

How To Tig Weld Aluminum

Aluminum is a complex material to weld, so that TIG welding can be challenging. Using this welding machine is difficult for newbie TIG welders. It is easy to get positive results when welding aluminum if you utilize the proper technique and follow the process.

As previously mentioned, welding aluminum is quite tricky, especially when dealing with long-lasting products and of high quality. Research indicates that TIG welding produces the best results when dealing with aluminum; this is because high-quality products can be created with the process. Aside from having excellent TIG welder knowledge, welders of aluminum must observe and consider some factors.

Basics of TIG Welding

The following is a small introduction to TIG welding basics before we discuss this process using aluminum welds. You can read down to the recommendations and techniques I provide if you are already familiar with this method. It will help you understand everything I am about to say if you first read a few lines.

In addition to tungsten arc welding, tungsten gas welding is another term for tungsten arc welding. Fusion is the process of joining two metal pieces into one. We are relying on tungsten electrodes, shielding gas, filler material, and an electric machine.

TIG allows the joining of different metallic materials. TIG welding is generally available for fixing stainless steel, aluminum, magnesium, and magnesium.

What Parameters Are Important in TIG Welding?

Many factors influence the welding process besides the welder’s technique. The weld materials are a part of some of the issues, while others are related to your equipment. The following principles are essential for beginners. You have to purchase the Aluminium TIG Welder to weld aluminium smoothly.

  • Shielding gas: The use of pure Argon is the preferred choice of 90% of welders worldwide. You can use these gases to weld stainless steel, aluminum, and carbon steel. For TIG welding, you can also use gas mixtures. In the presence of helium and argon, arcs become hotter.
  • Electrodes are sized according to their intended applications. Different electrode sizes perform better with different amperages and thicknesses of metal. As well, in some projects, electrodes that are not composed of tungsten may be more appropriate.
  • Gas flow: 20 to 30 cubic feet per hour of gas is typically needed for TIG welding. The larger the cup size, the more flow is required.
  • Current settings: A weld has to have current settings. People who want to learn fast or perform welds frequently have tons of machines online that offer advanced settings. No matter how unique the features in your machine are, two parameters always matter. Amperage and polarity are what I’m referring to. You should focus on those two issues.
  • Additional parameters: We can also consider some possible factors. Aside from the joint shape, consider the joint’s length, the thickness of the material, welding position, and base material.

Applications of TIG Welding with Aluminum

It might be curious to know what materials do TIG welders weld aluminum. You can find many applications for it in the industry, as it is a widely used technique. An example would be to weld thin-walled tubes or pipes. The bicycle industry has long used the method.

It is an ordinary welder’s tool for:

  • The frame of a bicycle
  • Heads of cylinders
  • Blocks of engines
  • Bungees for injectors
  • A rim
  • Radar
  • Intake manifolds

Weld aluminum foil with a spot or an arc weld. In addition to laser welding, micromachining can also be achieved by tuning the power of the laser.

With a Dynasty 200 and 1/16″ tungsten electrode, you can weld aluminum cans. As a filler, MIG wire can be used. Then, you can start at 20 amps. It is important to start the arc on the filler wire to avoid blowing a hole through the can. Start by running beads around the tank, switching the can to the next weld when a puddle forms.

Selecting Electrode and Filler Metal for TIG Welds on Aluminum

TIG welding uses tungsten rods as electrodes, as you are probably aware. In the melting process, tungsten does not become liquid. In some cases, you need to be careful to use pure tungsten electrodes because special conditions are required in the weld pool. Due to electromagnetic phenomena (not melting), tungsten molecules are brought into the weld hole. The process of welding aluminum is one of many unique applications.

Several electrode types may be helpful in different materials and thicknesses. The type of electrode used on aluminum will affect welding.

There are a variety of tungsten electrodes.

  • Throated
  • Zirconized
  • Tungsten pure
  • Created

Check out how these electrodes produce perfect aluminum welds—reviewing each one one at a time.

An electrode made of pure tungsten is best suited to use with AC rather than  DC. They can quickly round and ball these with ease because they are made of 99% tungsten. The aluminum alloys and magnesium alloys used here work best at low to medium currents. When welding aluminum, pure tungsten is the optimal electrode.

It has different additives such as hybrid combinations of oxides and is the latest type of tungsten. There is a better way in AC. This electrode is perfect for TIG aluminum welding, but it is not recommended for professionals.

White zirconiated metal: This metal is 99.1% pure tungsten and contains traces of zirconium oxide. In place of pure tungsten, this electrode type is used as it is resistant to contamination and can keep its balled tips. TIG aluminum welders should buy these electrodes.

The tungsten in this type of pellet is 97.3% pure tungsten and 2% thorium oxide, which has low radioactivity. Steel and other materials can be DC welded using this type of machine. I don’t recommend using aluminum in this way.

It is best suited to applications that use alternating current or direct current with inverter-based constant current power sources. At low amperages, they have a low erosion rate. A TIG aluminum weld utilizing this method is another good option.

What Polarity Should I Use

Defining the right setting for TIG welding isn’t as simple as it seems. There is a significant difference between the arcs at different polarities. Aluminum welding conditions are pretty crucial, which is why the most appropriate settings can make a big difference.

A current of electricity creates the arc in all types of arc welding. Several factors affect the way a procedure is carried out. Current can be classified as either DC or AC. There are different types of welding for different projects.

This short explanation will help you understand how AC and DC are different. In DC, electrons continuously move in one direction, while positively charged particles moving in the opposite direction are found in an electric arc. Electrons can move in either one of two directions in DC, called either DCEN or DCEP. As with DCEN, DCEP has a negative pole and a negative pole.

With AC, electrons turn back and forth at a specific frequency. Harmful particles, such as electrons, move in the opposite direction to positive particles. As a result, two opposite oscillations happen here: simultaneous oscillations varying in polarity from DC to DC negative in each circle simultaneously. DC negative circles are alternated with DC positive circles in each process.

AC or DC on Aluminum

Let’s figure out which type of TIG welding aluminum is better at the moment. In most cases, welders use either aluminum or magnesium as an AC  output. In general, stainless steel and steel, in general, are better suited to DC output. Moreover, In my opinion, AC is usually the best type of current for welding aluminum alloys and positions.


Stick welding and MIG welding use DCEP, or reverse polarity. It will still need electrode positive if it uses gas or metalcore without flux. Dual shield and metalcore can differ. Stick welding with DCEP generally results in a more stable arc when light penetration is needed; use DCEN if the electrode can run either polarity.

Frequency Suggestions for AC

It has been noted that AC is typically more advantageous in TIG aluminum projects than DC. DCEN and DCEP constantly fluctuate, which is a primary characteristic of AC. Several polarities change every second.

Due to its periodic nature, each complete cycle’s frequency depicts how many occur each second. Hertz is the reciprocal of a second, so frequency is measured in Hertz. I’m done with math. The welding industry has a lot to do with this.

A TIG machine allows the user to select the frequency of the current. Modern machines provide advanced settings without costing a fortune. 50 Hz, for example, completes 50 circles every second. A polarity shift occurs twice per period. Because of this, the alternation in polarity occurs 100 times every second.

High and Low Frequencies in TIG Welding on Aluminum

The frequency of welding affects the properties of the weld pool. Typically, TIG machines run at a frequency between 20 and 250  Arcs can also be created by applying high voltages and frequencies. A button ends this function on helpful elders.

High welding frequency allows for more precise arc control, more narrow weld bead shapes, improved cleaning, and a narrower arc cone. Using high-frequency welding is useful for welding curves, fillet welds, root passes, and even T-joints. In contrast, low-frequency welding leads to a broader arc profile that eliminates contaminants from the metal surface and broadens the weld bead profile. The metal deposition process is faster due to the highest transmission of energy to the workpiece.

What Amperage Should You Use for TIG Welding on Aluminum

As part of an arc welding process, the amount of current you use is a critical factor. You may know how to measure amperage. A wire and an arc pass current, measured in amps, through them. When welding aluminum, you use a pedal or fingertip control. Moreover, Num TIG welding requires you to know this number. A measure of electric current is counting amperes.

Amperage may be an issue when TIG welding aluminum. Weld penetration depends primarily on amperage. TIG penetrates very well because of the constant current it creates.

An amperage control pedal or a fingertip control is used for TIG aluminum. It is however necessary to set the amperage correctly in order to achieve the best results.  It requires between 60 and 90 amps to melt aluminum that is 1/1 inch in diameter. You will need between 125 and 160 amps if you are working with 1/8 inch aluminum. However, 3/16-inch aluminum requires 190-240 amps, while 14-inch aluminum requires 260-340 amps, and 3/8-inch aluminum requires 330-400 amps.

The TIG aluminum should have one Ampere per thousandth inch. Therefore, it would take 125 amps to weld a 12.5mm or 1/8 thick base material. As the material gets wider than 14 inches, the amp requirements change.

Suggested Voltage

An arc produces a lot of heat when a voltage is applied. A high arc voltage increases part power. The answer to your question is that it depends on what voltage you use for TIG welding on aluminum.

To start the arc, you need a high frequency and a voltage above 60 volts. With a lot of currents, high voltage is not practical. You can only use a certain amount of current to get a certain voltage. It is, therefore, safer to start at a medium to low voltage range, then calibrate accordingly.

What Gas Should You Use

The shielding gas is necessary for TIG welding. The surrounding air would contaminate the welding pool without shielding gas. People have used a variety of gas mixtures and gases when TIG welding. It might not be optimal or even suitable for you to select these gases more frequently than you believe.

A suitable gas can provide two benefits. In addition to making your life easier, the weld pool itself can come with essential features.

TIG welding is mainly conducted with Argon, Helium, and CO2. All of these suggestions are not my intent. As well as mixtures, you can find them. It is a list of aluminum-compatible gases.

Is Argon a Good Option

You may want to consider Argon when TIG welding aluminum. With this gas, you won’t encounter any issues with most aluminum alloys. You can create strong welds using this inert gas. It’s far cheaper than Helium, and once it cools, the seam properties are excellent.

If you are going to TIG weld aluminum, I recommend buying these pure argon canisters. This gas can save you a lot of time.

Is Helium a Good Option

I agree.  Titanium is an excellent material for TIG welding aluminum. The arc will be more stable, and it will perform better U.S. offers cheaper Helium for welders when cleaning. Helium at 100% or 100% Oxygen with My first choice would be 100% Argon. Welders prefer Helium because it is cheaper in the United States.

Are Argon – Helium Mixtures Any Good

You can GTAW aluminum more easily when you mix such mixtures. When welding with gas tungsten arcs, mixtures of 75 percent Argon and 25 percent helium are sometimes used. It can result in more incredible weld travel speeds. Instead of pure Helium, I would prefer such a mixture. This regulator lets you create custom gas mixtures. You can increase several of those gases, depending on your needs. Using the above formula, we will create a mix whose arc corresponds to your needs.

Is Carbon Dioxide on Aluminum Any Good

Aluminum and Carbon dioxide react to create oxides. In aluminum, both of these gases cause weak welds. CO2 is not recommended on aluminum welds.

How to TIG Weld Aluminum – Step by Step 

During the welding process, preparation is essential. TIG welding is easily cleaned up in several ways. For example, you can use these methods:

  • A hand pad
  • An electric brush
  • Pickling paste

However, it is not the most efficient method to work with hand pads. Brushes made of wire can also be used to get rid of more difficult contaminants. Almost all cases can be solved using either method. Pickling paste can also be used.

Steps for TIG Welds on Aluminum

For welding to be done correctly, the materials must be prepared first. Cleaning raw aluminum is necessary for several reasons.

A layer of oxide develops naturally on the exterior surface of aluminum as it’s cooled at the factory.

Cleaning Contaminants and Oils on the Surface

To prepare the aluminum surface for TIG welding, you need to perform the following steps:

First, keep the aluminum surface free of contaminants and oil. Pre-brushing is very important. Aluminum can be contaminated by brushing.

2: To remove aluminum oxide from the surface, brush the material. Aluminum’s oxide layer is usually not difficult to remove with a brush. Stainless steel brushes should be used.

Use Aluminum, Stainless Steel, and Steel tags to identify the brushes to prevent mixing them up. If you regularly apply a carbon steel brush to an aluminum material, you want to avoid accidentally doing so.

Machine Preparation

The welding machine settings must be appropriate. Alternating current is the best approach when welding aluminum, as I mentioned earlier. Welders who use pedals can set their machines to run at a higher current than they need. To control how much current you use, you adjust the amplifiers with the pedal.

A tungsten electrode will perform better and last longer since it is pure and durable. To prevent the electrode tip from breaking off and falling into the weld, the electrode must not be sharpened to a sharp point. Argon gas shielding is necessary to prevent distortion of welds and to achieve optimum welding performance.

The Process

Checklists should be prepared. These must be included:

  • Don’t leave anything that might catch fire around the workpiece
  • Amplify
  • Alternating current or A/C should be selected.
  • The coolant level should be checked on the machine.
  • Connect the hose to the cable of the TIG torch and secure it
  • Verify that the electrode is in good working order and that the stick-out is proper.
  • Ventilate the bottle of shielding gas.
  • You should adjust the flow rate of shielding gas as needed
  • Set the welding helmet to auto-darken when you turn it on
  • Weld without allowing the electrode to touch the base metal or weld pool.

Important Tip: Because there are many factors to keep in mind before you begin welding, making your list on paper and attaching it to the underside of the welder may assist you.

PPE or Personal Protective Equipment

Ensure that your PPE works properly by putting it on. Before welding, always ensure your protective equipment is functioning correctly. To perform TIG welding, you will need:

  • Glasses for safety
  • Protect your ears
  • Boots with steel toes
  • Welding helmets with automatic dimming
  • Fire retardant leather and coats
  • Gloves for welds
  • Fire-resistant headgear

Regardless of the items above in the TIG welding aluminum process, it is best to start with  the following items:

How to TIG Welding On Aluminum Pipe is Done

A wide variety of industries use aluminum pipe TIG welding, which is growing insignificance. Technique and execution are essential. The following are tips for TIG welding aluminum alloy pipes.

It is possible to walk the cup an aluminum pipe when welding around it for a root pass. To prevent arcs at the electrode, use a TIG cup for additional stability. The weld will be cleaner and more even with this technique.

It’s best to walk backward and forwards when using the electrode on the cup to provide deeper penetration into the metal for a root pass. In advancing, the filler metal will go deeper into the joint. In contrast, the motion of going backward will provide extra heat to ease in.

The hot TIG welder can alter aluminum, but if you want a strong fusion with the aluminum, don’t be afraid to run it hot enough to break down the edges of the metal. It is essential to learn how to weld using lots of heat without damaging the materials by running too cold. Avoid turning it up too hot so as not to ruin the machine.

You can weave the weldings in by adding the extra passes along the aluminum pipe. Using cursive or a side-to-side arc is the most effective way.

What’s the Heat Input of TIG Welding on Aluminum?

The welding of aluminum plates, often utilized in chemical and cryogenic processing, is standard practice in structural and nonstructural applications. As a result of TIG welding alloys that are responsive to welding heat, porosity and solidification cracking are common defects. There has been a divergence from 0.89 in heat input sets. There are many suitable welding gloves o 5 kJ/mm resulting from the combination of torch travel speed and welding current.  One to two KJ//mm of heat is usually sufficient.

It’s crucial to protect workers from the powerful heat of TIG welding but not to lose their touch sensitivity. Dexterity is, therefore, a requirement. A good pair of gloves and TIG fingers can prevent power heat from occurring. Welding gloves have a wide range of advantages, so make sure you get one that meets your needs, You can also purchase good laptop in reasonable money.

TIG Welding Aluminum Machines

TIG welders that run on AC power are excellent for welding aluminum. You can find many excellent prices for these. Clean starts, smooth arcs, user-friendliness, and other essential features are essential factors in the best aluminum TIG welding machines. Below we have outlined a few of the best current TIG aluminum welding machines on the market:

Lotos TIG/Stick Welder: 

With this machine, you have all the necessary features for almost all TIG or stick welding applications, as well as TIG non-contact arc initiation. The HF arc starter provides consistently reliable arc starts. Installing this boosts productivity and is accessible. This type of electronic control system offers the convenience of plugging in the input voltage without requiring manual connection. The power that is unreliable or dirty can be solved with this device.

Forney Easy TIG Welder: 

It is perfect for home use. It’s one of the most reliable machines for their price.

Lincoln 210: 

The MIG welder is perfect for educators, contractors, and professors who like to perform MIG welding. For quick and easy operation, it has a push-button control system and a color touchscreen.

Miller Multimatic 215: 

Effortlessly add GIG, TIG, and stick welds to your build skills with this user-friendly machine. Featuring an auto-set elite screen, it has a color display. Powered by 120 to 240 volts, this is your all-in-one welder that will weld mild steel up to 3/8 inches thick.

TIG Weldability Between Aluminum And Bronze Alloy

The corrosion-resistant, lightweight, and weldable properties of aluminum make it a very popular metal. Alloys can be as strong as steel despite their low strength. It is possible to combine bronze alloys in a variety of ways. As a result, bronze alloy properties need to be understood.

Aluminum is particularly prone to profile imperfections because of its high thermal conductivity and fast-curing weld pools. You should use the correct welding technique and parameters to minimize the risk of undercutting, inconsistency, or inadequate penetration.

You can use the metal forehand as one helpful technique.  Cast iron, steel, copper, and aluminum bronze rods easily coat cast iron, steel, and copper surfaces in addition to providing excellent wear resistance.

TIG Weldability Between Aluminum And Steel

Compared to steel, aluminum weighs about 2.70 grams per cubic centimeter instead of a density that varies from 7.75 to 8.05 grams per cubic centimeter. Therefore, comparable steel volumes consider three times more than aluminum volumes.

Arc welding aluminum to metals such as steel does not work with mechanical fasteners or adhesives. Straight Aluminum becomes extremely brittle after welding when you head copper, steel, titanium, or magnesium. By using arc welding, aluminum can resist brittle compounds from softening.  Aluminum and steel require bimetallic transition inserts.

Utilizing bimetallic compounds allows for the creation of a bridge between aluminum and steel. Consequently, there will be two separate welds. Aluminum and transition metal are the first two. Second, the transition metal is between steel and iron. Also, you can arc weld the piece with aluminum and coat it with silver or aluminum solder. There are no ideal methods described here, and there is a need for more complex processes such as explosion welding.

TIG Weldability Between Aluminum And Titanium

Welding aluminum and titanium requires an alloy or a filler that adheres to the boundary between the two metals. With enough welding energy, both metals will soften.

You should be aware that temperatures can go up to  2000 degrees Celsius. Furthermore, the aluminum filler has a maximum titanium content. It’s possible to use titanium up to ten percent in most situations. Finally, both metals should exhibit discontinuous phases.

Top 6 Aluminum Welding Tips

1. Preheat the aluminum

The type of aluminum determines how much preheat should be done. Preheating aluminum with a high density is necessary while heating aluminum with a low density is not necessary. With aluminum, pre-heating is the most popular option for TIG welders who want quality results. Using preheating and welding machines, ideal welds will be made.

2. Clean the tungsten electrode

Regularly cleaning tungsten electrodes is essential. It is possible to expose equipment faultiness by contaminating the electrode quickly. Moreover, It will result in a lower-quality weld. It is usually spread on a flat surface with the contaminated end at the edge to clean the tungsten electrode. A hammer is then used to remove the infected portion.

3. Use a heatsink

A heat sink that absorbs too much heat destroys aluminum samples. It is difficult to weld aluminum with heatsinks. Copper or aluminum heat sinks can prevent such incidents.

4. Use an AC polarity

A layer of aluminum oxide is easily formed, which is difficult for the naked eye to spot. When welding aluminum, TIG welders must keep this in mind. Once welding starts, the layer will likely develop back despite cleaning the oxide layer with a carbide cutter. The coating can make TIG welder aluminum ineffective. Thus, AC polarity has advantages since the flow forward of the current keeps alternating. Through the AC polarity, the welder can eliminate the oxide layer continuously.

5. Set the appropriate balance control

It is important to balance aluminum before welding. There are both positive and negative cycles in an electric welding machine. It is on the negative side where you are going to find the AC and the oxide layer is on the other side. To work correctly on the weld material, it is therefore important to set the balance perfectly. It is sometimes necessary to lower the negative side of the polarizer for aluminum samples with thick oxide layers in order to clean the oxide layer more effectively.

6. Use the correct amperage

For quality results, it is important to use an amperage that matches the welding machine. By controlling the wattage, one can create an elegant aluminum device. The sample width determines varying voltages. The energy requirement for some samples is more significant than others.

TIG welders working with aluminum should possess the necessary information. It is essential to be patient when working with aluminum. A high standard of equipment requires both of these qualities. Aluminum welding is a very important skill, so if you want quality products, do your best to consider the above tips.

Frequently Asked Questions

Do you TIG weld aluminum on AC or DC?

To weld, Mild Steel and Stainless Steel will need DC; while welding Alu will need AC. According to the type of connection, TIG welding uses three different welding currents.

Do you push or pull when TIG welding aluminum?

If joining stainless steel, aluminum, or steel, use oxygen gas when welding TIG. For TIG welding, you should always use the push method, even though pull works well for MIG.

What do I need for TIG welding aluminum?

For TIG welding aluminum, a shielding gas (usual argon) is necessary, as well as a tungsten non-consumable electrode and a clean surface. It is necessary to remove the oxide from aluminum before welding since the melting point of the oxide is higher than that of aluminum.

What Rod do I use for aluminum TIG welding?

TIGLAW rods made from aluminum

The most versatile rod for castings is the 4043 aluminum tig rod. It is perfect for castings made of 3003, 6061, or A355 aluminum. And get some 4047 rods for castings where porosity occurs. Silicon makes up 12% of 4047. As a result, it flows better and cracks less.

Can aluminum be welded with DC TIG?

It is almost always an alternate current (or “AC”) used in TIG welding aluminum. It is also possible to TIG weld aluminum using direct current (also called “DC”). TIG aluminum can sometimes be welded better with DC.

Can you scratch start TIG aluminum?

TIG welding with DC(+) on aluminum can result in the following: After scratch starting and maintaining an arc, your tungsten will begin to the ball, and then the aluminum oxides will dissipate as you get half of a cleaning cycle.


Finally, you have learned How to TIG Weld Aluminum. You should be able to weld aluminum today using this guide. Other articles about welding and CNC machining also contain the same types of guides like this one.


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